Cutting 1/4" Lexan

[Trouthunter]

I'm trying to find a way to build a box out of Lexan, and 1/8" is too brittle. I can score 1/8" to break it, but I'm wondering how to cut 1/4" lexan? Are there shops that will cut this stuff for a charge?

If I use any type of saw, it makes a huge mess of molten plastic. Not the way to get any type of "clean" edge.

Anyone have any experience or advice?

BD

[waskawood]

I am not sure if Lexan and plexiglass are the same or not. I used to cut lots of plexiglass with a fine toothed band saw and it didn't leave a molten mess. Maybe the speed is too fast if it is melting everything.

[Gissert]

I cut plexi all the time on my tablesaw. Works pretty good, and you get nice square cuts.

[ozzy]

Lexan is poly carbonate material.

If you cut on a table saw turn your blade around or run it thru backwards.

I jig saw with a plastic blade will work.

On the edges you can sand them smooth, then bring the clear back with a propane torch, it might leave some black soot in it.

Try a scrap piece and see how it works.

[Jeremy airjer W]

table saw or circular saw with a fine tooth blade made for plastic/laminate, (all we used at the sign shop), Jig saw with a plastic blade, Spiral saw (roto-zip). A straight edge and a circular saw would probably give you the best results for the least amount of investment.

Just be carefull cleaning up the edges with the torch! It does work but I've seen a few projects get trashed after busting out the torch.